JLG Lull 1044C-54 II Series Service Manual page 170

Boom and Transfer
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5. Remove the cylinder rod assembly from cylinder barrel.
CAUTION: To prevent possible damage to components, support cylinder
rod assembly; do not wiggle rod or head back and forth during
removal.
6. Remove rod nut (Item 4), piston (Item 5), tube (Item 6), and rod
bearing head from rod (Item 8).
7. Inspect bushings for damage. The following steps are necessary if
bushing(s) need to be replaced:
a. Remove bushing (Item 9) from cylinder rod using a bushing driver
and hammer or press.
b. Install new bushing so that it is centered in rod end opening.
c. To ensure proper lubrication, make sure an adequate amount of
grease is applied to the grease fitting after cylinder is reinstalled on
machine.
8. If necessary, remove grease fitting cover (Item 11) and grease fitting
(Item 10) from cylinder. Inspect and replace if damaged. Install and
tighten fitting 1.5 to 3 turns past finger tight.
9. Remove all O-rings, wear rings, and backup rings from cylinder
components and discard.
10. Thoroughly clean components with solvent and dry with compressed
air.
11. Inspect inner surface of barrel, outer surface of piston, and length of
rod for scratches and scoring. If barrel, piston, or rod is damaged, it
must be replaced.
12. Check condition of threads on rod and rod nut. Do not attempt to repair
damaged threads.
13. Lubricate new O-ring with hydraulic oil and install inside piston (seals
rod to piston).
14. Lubricate new O-ring, backup ring, seals, and wear rings with hydraulic
oil and install on rod bearing head. Using a seal driver, install new
wiper seal in head. Lubricate wiper seal with hydraulic oil.
15. Slide rod bearing head (Item 7), tube (Item 6) (see note after Step 6),
and piston (Item 5) onto rod (Item 8). Lubricate threads on rod with
hydraulic oil and install rod nut (Item 4). Torque rod nut as follows:
550 ft-lbs.
16. Lubricate new seal and wear rings with hydraulic oil and install on
piston.
17. Apply removable (blue) thread locking adhesive to threads on (1) set
screw (item 3) Coat inside of cylinder barrel (Item 2) with hydraulic oil.
To avoid damaging seals during assembly, carefully insert cylinder rod
assembly into cylinder barrel.
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